Design and Performance Evaluation of an Industrial Nozzle for Abrasive Jet Micro-Drilling of Glass
Keywords:
Abrasive Jet Machining (AJM), Micro-Drilling, Nozzle Design, Material Removal Rate (MRR), Computational Fluid Dynamics (CFD), Stand-off Distance (SOD), Glass Machining, Process OptimizationAbstract
This study presents an integrated computational and experimental investigation of abrasive jet machining (AJM) for micro-drilling of glass plates using a standard industrial nozzle. Computational Fluid Dynamics (CFD) simulations were performed to analyze abrasive particle flow behavior, velocity distribution, and impact characteristics within the nozzle. Experimental trials based on a Taguchi design were conducted to evaluate the effects of key process parameters, including jet pressure, abrasive feed rate, stand-off distance, abrasive type, and grain size. The results show that jet pressure has a strong influence on material removal rate (MRR), while abrasive feed rate and stand-off distance significantly affect hole accuracy and surface quality. Optimal machining performance was achieved at a jet pressure of 5.5–6 bar, abrasive feed rate of approximately 3 g/s, and stand-off distance of around 1.5 mm, producing holes with high dimensional accuracy (~2.00 mm), low surface roughness (~0.9 µm), and minimal taper (<2°). The study establishes a correlation between CFD predictions and experimental observations, providing a reliable framework for process optimization. The findings contribute to the development of practical guidelines for high-precision AJM micro-drilling in brittle materials such as glass.
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Copyright (c) 2026 Om Kamble, Harshad Savant (Author)
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